Axial gap type rotary electric machine and manufacturing method thereof

Abstract

An axial gap type rotary electric machine includes a rotor and a stator. The rotor has a support plate and a permanent magnet disposed on the support plate. The support plate includes an inner core. The inner core includes a plurality of vertical walls. The plurality of vertical walls are disposed in a radial shape. The plurality of vertical walls are disposed in a rotationally symmetrical with respect to a central axis. The plurality of vertical walls are positioned behind the permanent magnet. The plurality of vertical walls function as members that resist axial force and radial force acting on the permanent magnet.

What is claimed is: 
     
         1 . An axial gap type rotary electric machine, comprising:
 a stator and a rotor which are magnetically coupled in an axial gap in an axial direction,   wherein   the rotor includes:   a permanent magnet disposed to face the axial gap;   a support plate disposed behind the permanent magnet, wherein   the support plate is positioned behind the permanent magnet, is disposed in a rotational symmetry with respect to a central axis of the rotor, and has a plurality of vertical walls extending in the axial direction.   
     
     
         2 . The axial gap type rotary electric machine according to  claim 1 , wherein the plurality of vertical walls are disposed in a radial shape so that each of the vertical walls extends along a radial direction. 
     
     
         3 . The axial gap type rotary electric machine according to  claim 2 , wherein
 the support plate includes:   an inner core having the plurality of vertical walls; and   an end plate joined to at least one end surface of the inner core.   
     
     
         4 . The axial gap type rotary electric machine according to  claim 3 , wherein
 the plurality of vertical walls include a plurality of radial vertical walls extending along the radial direction.   
     
     
         5 . The axial gap type rotary electric machine according to  claim 4 , wherein
 the plurality of vertical walls include only the plurality of radial vertical walls.   
     
     
         6 . The axial gap type rotary electric machine according to  claim 5 , wherein
 the inner core includes a plurality of cylindrical members disposed in a radial shape along a circumferential direction.   
     
     
         7 . The axial gap type rotary electric machine according to  claim 4 , wherein
 the plurality of vertical walls include:   the plurality of radial vertical walls; and   a plurality of intersecting vertical walls extending in a direction intersecting the radial vertical wall.   
     
     
         8 . The axial gap type rotary electric machine according to  claim 4 , wherein
 the inner core includes a wall member which defines a plurality of cells having N-sided shapes, where N is the natural number of 3 or more, by the plurality of vertical walls in a cross section perpendicular to a central axis, wherein   at least one of the plurality of vertical walls that defines the cells is the radial vertical wall.   
     
     
         9 . The axial gap type rotary electric machine according to  claim 8 , wherein
 the plurality of cells include hexagonal cells.   
     
     
         10 . A method of manufacturing the axial gap type rotary electric machine according to  claim 1 , the method comprising:
 assembling the support plate;   connecting the support plate and the permanent magnet to assemble the rotor; and   assembling the rotary electric machine by facing the rotor and the stator at the axial gap, wherein   the step of assembling the support plate includes:   stacking step of stacking a plurality of strips so as to be joined by a plurality of joining layers;   expanding step of expanding the plurality of strips from a stacked member obtained by the stacking step in a circumferential direction while bending the plurality of strips to form an inner core having an annular shape; and   step of joining the inner core and an end plate.